WO2008103021A2

WO2008103021A2 - Device and method for producing a food item of rolled dough

Info

Publication number: WO2008103021A2
Application number: PCT/MX2008/000023
Authority: WO
Inventors: Joaquín FERNANDEZ BAUMEISTER; Armando SEDANO HERNÁNDEZ; Elizabeth Quintana Romero; Irene Cruz Leyva
Original assignee: Sabritas, S. De R.L. De C.V.
Priority date: 2007-02-21
Filing date: 2008-02-21
Publication date: 2008-08-28
Also published as: CA2678223A1; NI200900160A; AR065415A1; BRPI0808010B1; EP2140997A4; EP2140997B1; ZA200905801B; CR10972A; US7585531B2; US7950916B2; CA2678223C; PA8865201A1; US20080199569A1; GT200900232A; US20090311391A1; EP2140997A2; BRPI0808010A2; ES2549867T3; WO2008103021A3; PL2140997T3

Abstract

The invention concerns an improved method and device for producing a rolled snack, using an extruder which typically has a plurality of apertures, through which an extruded product exits the extruder. Each aperture is in the shape of a spiral. When the desired length of the stream or strand of extruded product exits via an aperture, the strand is cut at the base, thereby producing individual snack items which appear to have been rolled after the layering process.

Description

APPARATUS AND METHOD FOR THE PRODUCTION OF AN ENROLLED MASS FOOD PIECE

BACKGROUND

1. TECHNICAL FIELD

The present invention relates to an apparatus and method for forming dough tubes that resemble, when cut, a rolled dough product. Specifically, this invention relates to a method and apparatus for producing rolled dough pieces using an extrusion die having a spiral orifice pattern.

2. DESCRIPTION OF THE RELATED TECHNIQUE

Rolled products are found in many different food industries such as crescent buns, waffle bars, flutes and frozen / stuffed taquitos. Many of the prior art procedures have been developed to address the complexities of winding each of these products. For example, the crescent roll industry generally uses a relative speed differential between two bands. The crescent roll industry uses relatively thick dough with a high degree of stickiness, which makes it Absolutely easy to manipulate. In contrast, the wafer bar industry typically uses a milkshake or pastry mixture that is dried by means of a drum, is wound around a mandrel at an angle of 45 degrees, and then cut into pieces.

In the snack food industry, however, the dough typically used comprises one or more starches and / or flour, said dough is then formed into very thin sheets, cut into pieces, and then roasted, fried and / or baked. Typical types of dough include, but are not limited to, the following: potato, rice, corn and wheat based doughs. It is particularly desirable to produce a cylindrical sandwich piece, typically made of a thin sheet dough that is roasted and / or fried, and seasoned. The dough used in said snack products, unlike the dough used in other food industries, is generally very thin, fragile and difficult to handle. This makes the typical winding technology unacceptable for said application. In addition, the processing speeds required in the snack food industry are very high in relation to other industries, making rolling the dough even more difficult when using a laminated starting material.

Although hanging curtains have been used in the technique In order to roll dough sheets, the existing prior art devices suffer from a less complete winding of the product when the dough sheets fail to separate from the transport surface when coinciding with said hanging curtains. In addition, the prior art dough rolling devices lack the ability to produce rolled products from thin dough pieces reliably, efficiently, and at high volume and high speed. For example, US Patent No. 6,393,974 B1 (Ia "patent 974"), entitled "Apparatus for the Production of a Small Tortilla", is directed to an apparatus for rolling raw tortillas in the form of a taco. Although the '974 patent describes the use of hanging curtains on flat conveyors, there has never been a ramp mass winding apparatus to allow a more reliable and complete winding. The '974 patent refers to an apparatus for rolling dough that has a "pre-winding mesh" and a "final winding mesh" and repeatedly emphasizes the need for said meshes to be placed on an "acceleration conveyor belt" that operates faster than the preceding "conveyor belt". For example, the '974 Patent in column 4, lines 53-55, states that "[n] ext towards the conveyor belt 106 it is an acceleration conveyor belt 108 with a cross-sectional area that advances at a speed greater than the output conveyor belt 106 ". In column 5, lines 6-14, the patent" 974 continues, "pre meshes are placed. winding 1 19 with a small contact surface and are dragged with the mesh of the acceleration conveyor belt

108 The final winding meshes 120 show a larger contact surface and are dragged with the acceleration conveyor belt 108 .... ". The operation and maintenance of an acceleration conveyor belt in addition to a rolling conveyor conveyor belt are undesirable, since it introduces another point of transfer of potential product, where problems can occur.The addition of a second conveyor belt of an operating speed different from that of the system can also increase the complexity of the control procedure and capital expenditure. Patent '974 also establishes in column 1, lines 58-63: "the adjustment of the speed of the output conveyor belt is required together with modifications to the rollers. The new laminator structure eliminates the versatility of said conveyor belt and makes the laminator unable to be used later, since other types of products require speed through which the laminator is re- designed".

Other apparatus of. Dough wrapping of the prior art is described in US Patent No. 6,171, 628 B1 (Patent 628 "), which was issued on January 9, 2001 and is entitled" Method for Rolling a Dough Sheet ". Although the '628 Patent describes the use of hanging curtains to induce the dough sheets to be rolled, the' 628 Patent actually teaches in addition to the use of hanging curtains and rather is directed to a winding roller to wind dough sheets. See the '628 Patent in column 1, lines 38-40; Figures 7a, 7b and 7c of the' 628 Patent (illustrating common binding problems with the mass winding curtains).

U.S. Patent No. 6,079,970 (the "970 patent") issued to Ueno on June 27, 2000, entitled "Apparatus for Rolling a Dough Sheet". As the '628 patent above, the' 970 patent actually teaches and discourages the use of hanging curtains and rather is directed to a winding roller for rolling dough sheets. See Patent '970 in column 1, lines 35-37; Patent '970 Figures 7a, 7b and 7c.

US Patents Nos. 4,994,293 (the "patent '293") and 4,905,583 (the "patent'583") granted to Hayashi on February 19, 1991, and March 6, 1990, and entitled "Method for Rolling Dough Pieces "and" Apparatus and Method for Rolling Half Moon Sandwich Dough Pieces ", respectively. Patent '583 and Patent' 293, which is a divisional application of Patent '583, both are addressed to an apparatus and method for winding triangular dough pieces into half-moon sandwich shapes using a flexible hanging sieve. Patents '293 and' 583 emphasize that the dough pieces are to be stretched and transferred to an unreduced winding apparatus significantly to the adhesion of the dough pieces Although the methods of the prior art for rolling dough pieces to half-moon sandwich shapes employed the use of flour to make the dough pieces less adhesive and more easily handled, the '293 Patents and '583 teach that such loss of adhesion is disadvantageous in producing closely wound half-moon sandwiches.' 293 and '583, however, do not provide a means to Ensure that the mass winding curtain effectively initiates a winding action, nor does it offer solutions to the problems of carrying out a more complete winding and avoiding the clogging of the product along the flat surface of the mass winding conveyor belt. Although it is possible to use a single mass rolling curtain to roll a piece of rolled dough, said The device tends to have lower winding efficiency and lower production than is desirable.

U.S. Patent No. 4,666,319 (the "patent '391") granted to Watt et al. On May 19, 1987, and entitled "Apparatus for Rolling a Paste Layer and a Separator Sheet". The '391 Patent is directed to an apparatus for forming rolled pastes having a film interposed between adjacent rolled layers to inhibit the layers from adhering to each other. Although the '391 Patent describes the use of an individual mass induction member as a winding device on a flat transport surface, the' 391 Patent does not address the problem of binding, which occurs when the sheet mass fails to separate of the transport surface after coinciding with the drag induction member.

The US attempt No. 4,389,176 (the "Patent '176") granted to Nenci on June 21, 1983 and entitled "Machine for the Production of Tubular Covers of Food Dough". The '176 Patent refers to a dough wrapping device where pieces of dough are wrapped around support cores to form cannon tubes. Although the '176 Patent describes the use of a metal mesh sieve as a mass winding device, the metal mesh of the Patent '176 is supported and maintained between two rollers. See Patent '176 in column 6, lines 26-30. A flat mesh screen shown may not be suitable for thin and fragile doughs such as corn dough in the form of a thin sheet, since said flat sieve can unduly concentrate winding forces and pressure in the minimum contact area between the flat screen and rolled dough products. This could probably result in the destruction of the fragile mass product. In this way, a flexible chain or mesh curtain is critical for rolling fragile dough pre-forms.

US Patent No. 7,156,642 (the "patent '642") issued on January 2, 2007, and entitled "Apparatus and Method for Rolling Dough". The apparatus described in the '642 Patent comprises an apparatus for rolling dough having a dough sheeter, a receiving conveyor belt having a ramp section, a roll initiation curtain placed above the ramp section just downstream of the peak of the ramp, and a roll completion curtain placed under the roll initiation curtain. A ramp mass winding conveyor belt solves the problem of jamming of pre-forms (rolled and cut dough pieces) and roll fall as they pass through under the first curtain or group of curtains. Although the '642 Patent is an improvement with respect to the prior art in this field, careful attention is required for several of the components of the' 642 Patent apparatus in order to maintain a consistently rolled product. For example, if any mass develops on the winding curtains, the shape of the final product is altered. As with any rolling arrangement, mass development emissions in components are always present, thus requiring frequent cleaning.

Consequently, there is a need for an apparatus and method that can produce a rolled dough product, consistently, and with some components making contact with the dough, in order to avoid mass development emissions. Said apparatus and method must also be capable of producing a dough-based snack product at a high production rate in accordance with the economy of the snack food industry.

BRIEF DESCRIPTION OF THE INVENTION

The invention comprises a method and apparatus for producing a rolled dough product. This rolled dough product is formed as individual pieces with the appearance of a flute or taquito shape. The pieces are formed by extruding a food dough through a spiral shaped hole. The extrudate is cut into individual segments, thus forming individual food pieces. These pieces can then be cooked, typically fried.

By forming these parts using an extruder, as opposed to a rolling process, many of the problems found in the prior art are overcome. The procedure is simple, efficient, and provides high product production. A complex rolling, cutting and winding apparatus is not required. The emission of mass development typically encountered with rolling operations is avoided. The invention produces a product consisting of few components making contact with the dough and in a highly complementary way with the economy of the snack food industry.

Other aspects and benefits of the present invention will be evident with the following detailed written description.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel aspects that are considered characteristic of the invention are set forth in the appended claims. However, the invention itself, as well as a mode of use preferred, other objects and advantages thereof, will be better understood by referring to the following detailed description of the illustrative modalities when read together with the attached drawings, where: Figures 1 a and 1 b are plan views of a modality of an extruder die insert of the present invention;

Figure 2 is a perspective view of the extruded product leaving an extruder die according to an embodiment of the invention; Figures 3a and 3b are perspective views of a product made in accordance with an embodiment of the present invention;

Figure 4 is an exploded view of an extruder die insert assembly according to an embodiment of the present invention;

Figures 5a and 5b are views of the front and rear of a die insert assembly according to an embodiment of the present invention;

Figure 6 is a side view of an extruder of the prior art and cutting mechanism; Y

Figure 7 is a plan view of the extruder die face according to an embodiment of the present invention. DETAILED DESCRIPTION

The invention of the applicant produces a snack food type piece, which has a rolled appearance, but is not rolled through the manufacturing, at least not through the methods used in the prior art. Rather, applicants use extrusion technology to produce a food piece that provides the appearance of having been rolled from a lamination process.

Figures 1 a and 1 b show the front part (exit) and the rear part (entrance), respectively, of an extrusion die insert 102 according to an embodiment of the Applicant's invention. Referring to Figure 1 a, the die insert 102 is shown in a plan view from the perspective of the outlet portion of the spiral hole 104 of the Applicant. Figure 1b, again a plan view, shows the opposite side of the die insert 102, thus revealing the inlet opening towards the hole 106 in a spiral shape. It should be noted that the inlet 106 to the hole is wider than the outlet 104 of the hole. The internal width of the hole between the inlet 106 and the outlet 104 gradually and linearly is reduced from the width of the inlet 106 to the width of the outlet 104, in the illustrated mode. This reduction in width allows the introduction of the extruded product into the insert of 08 000023

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given 102 from the extruder and facilitates the pressure differential between the extruded exit product and the extruded product inside the extruder. The typical width of the outlet portion of the hole 104 is between 0.5 mm and about 3.0 mm, and the width of the inlet 106 about twice the width of the outlet 104.

The operation of an individual die insert with respect to a larger extrusion device will be explained later. Referring to Figure 2, however, the die insert 202 is shown together with an extruded material 208 that emerges from the spiral-shaped hole. This extruded material 208 (or extrusion material), when extruded at high speeds, essentially forms an extruded mass or filament, which in its cross section, is spirally shaped. After leaving the extruder at approximately the length shown in Figure 2 (about 3.0 mm to about 3.5 cm in an embodiment that is about 0.9 cm wide to about 1.3 cm), the extruded filament is cut through known means in the technique along the surface of the die insert 202. The cutting of the extrudate 208 into individual pieces produces a rolled dough product that can then be cooked, typically, fried, through means known in the art.

Referring to Figures 3a and 3b, a typical snack-type part 308 formed through the Applicant's method and apparatus is shown. The individual piece 308 has a first end 312 and a second end 310. It should be noted that the second end 310 is generally a flatter surface, since the second end 310 results from the cutting of the extruded product on the face of the die insert as described above. The first end 312 of the piece, therefore, is first formed by emerging from the die insert immediately after the previous piece has been cut along the face of the die insert. The variations in the axial flow rate of the extruded product through the hole result in a slightly irregular shape of the first end 312 of the piece. Also in Figure 3a, a slightly open skirt 314 is shown. This slightly open skirt 314 may be desirable in order to give the food piece a shape that is more favorable for using the piece 308 as a ladle or hand shovel for various dressings, and sauces. The shape of this skirt 314 depends on the mass material used, the various processing parameters through the extruder, and the shape of the hole of the die insert. An additional insert hole mode given that it provides a more open skirt 314 is discussed below with respect to Figures 5a and 5b. Typically, the piece can vary in length from 1 cm to 40 cm and a width of 0.5 cm to 3.0 cm. Referring to Figure 4, an exploded view of a formation die insert 402 and its separation die insert 420 is illustrated. This particular forming die insert 402 has six individual spiral-shaped holes, 406, over an individual insert. The formation die insert 402 coincides with the separation die insert 420 and maintains an appropriate position with it through two posts 424 on the separation die insert 420 which are received by two ports 426 on the die die insert. formation 402. The purpose of the separation die insert 420 is to channel the flow of extruded product from the extruder body to the discrete dough channels through corresponding openings 422 that coincide with, and direct the flow into the individual holes 406. Consequently, during operation, a mass of extruded product first flows through the openings 422 of the separation die insert 420 and then through the holes 406 of the formation die insert 402. Figures 5a and 5b show an alternative embodiment of a die insert assembly. Figure 5a shows, in a plan view, the formation die insert 502 with several individual holes 504 in a spiral shape having a slightly different shape to that shown in Figure 4. In particular, it can be seen in Figure 5a that each hole 504 in the form of a spiral has a tail or extreme Proration 505 which, when viewed from the outside of the spiral, inverts the curvature of the spiral 504 from convex to concave. Consequently, the hole 504 in the embodiment illustrated in Figure 5a is said to have a concave end portion 505. The use of the term "concave end portion", by the Applicants, is intended to describe the portion 505 of the hole 504 illustrated in the figure 5th. A die insert having this concave end portion produces an end product with a block shape.

Figure 5b shows how the die assembly matches the openings 522 of the separation die insert 520 with the hole 506 of the formation die insert. It should be understood that more than one separation die insert can be used with the Applicants' training die insert, but Applicants have illustrated an individual separation 520 insert 520 as a modality. preferred. The extrudate flows through the openings 522, then into the spiral hole 506.

Figure 6 shows a side view of an assembly of a tube return extruder 610, bell 612 and die 614 of the prior art. During operation, the product, such as the mass, is forced through the turn of tube 610 towards the bell 612. It is then extruded through the die 614. An arrow 616 extends through the turn 610, the bell 612. and die 614. Mounted on the end of arrow 616 is a cutting mechanism. The cutting mechanism comprises a hopper 630, rays 632 extending from the hopper 630, and blade supports 634 attached to the rays. Each blade holder 634 in turn maintains a blade 636 in contact with the die 614. Figure 7 shows a plan view of the die face

715 of an embodiment of the invention of the Applicants. The die face 715 will typically exhibit a number of die inserts 702 having at least one hole each, thus allowing product communication from the bell, through the die 714, and on the die face 715. As the product leaves these holes, it is cut into relatively uniform pieces through the blades 736 as the entire cutting mechanism revolves around the arrow in the direction 740 illustrated in Figure 7. Said rotation 740 is typically at speeds ranging from fifty to three hundred rpm, with approximately one hundred and forty rpm generally used to cut the extruded product from dough. It should be understood that the cutting mechanism shown in Figure 7 is, but one of several modalities of the cutting devices of the prior art, which can be used to cut the extruded product as it exits the holes. For example, oscillating blades or cutting cables can also be used.

It should be understood that any direct low pressure or high pressure extrusion process (pneumatic, hydraulic, vertical, horizontal, or pump driven extruder) can be used to push the mass of extruded product through the forming die to form the food pieces according to the invention of the Applicants. In a preferred embodiment, a vertical extruder is used, such as a vertical extruder through which an individual piston, in an upright position, pushes and advances the mass of extruded product against the forming die and, therefore, forcing its flow through the hole. A typical reciprocal pressure in said extruder, using corn-based doughs and the Applicants method, is approximately 21.09 kg / cm2 at approximately 84.36 kg / cm2, depending on the flow rate chosen from the extruder.

The conditions of the procedure can be varied to obtain different textures and flavors of the product. Some of these process conditions include the degree of cooking of the base material before extrusion, the temperature of the extruded product, the humidity of the extruded product, the particle size distribution of the extruded product, the length of the piece produced, and the cooking time and temperature

In a preferred embodiment, a corn-based nixtamal flour, such as Maseca flour, is mixed with water at a mass moisture level of between 45% to 55% by weight, or preferably about 49%. If the dough has too much moisture, it will lose its shape as it leaves the dice. Conversely, if it has very low humidity, it will stick to the extruder, die or other equipment. A typical mixing time of the flour with water is about 10 to about 30 minutes in a low shear mixing operation. The purpose of this mixing step is the hydration of the flour.

Another modality uses dough made from fresh corn. This dough, in a preferred embodiment, is made of a combination of yellow and white corn (typically a 50/50 combination). It is cooked with an addition of 1% by weight of lime until it has a moisture content of approximately 36%, which typically takes 6-8 minutes. It is then soaked until the moisture content is approximately 45%, which normally takes approximately 12 hours. The corn is then drained from the water and washed. This whole corn, cooked, soaked and washed is then transported to a drainage band to a corn mill that has a mill hole set between 0.04318 centimeters and 0.0508 centimeters as the target. Water with the corn is added to the corn mill in order to bring the total moisture level by weight of the resulting corn-based dough to between 45% to about 51%, with the same consideration for shape retention and stickiness of mass as described above.

In a preferred embodiment, the corn-based dough is then extruded as previously detailed. The temperature of the dough in the extruder varies from about 18 ⁰ C to about 28 ⁰ C for the mass of corn nixtamal flour and from about 3 ⁰ C to about 4 ^{0 0} C for fresh ground corn dough. The filament of the extruded product is cut into individual pieces as it exits the extruder, preferably over a length of approximately 3.0 cm to approximately 7.0 cm. In the preferred embodiment, these food pieces are then immediately fried in hot oil, typically with a fryer temperature of about 19O ⁰ C to about 198 ⁰ C. The residence time in the fryer for a typical product produced by the preferred mode of Applicants is between 25 seconds to approximately 60 seconds, depending on the size and texture and flavor desired. Individual food pieces are typically fried at a humidity level of about 1% to 3%. The pieces are then seasoned and packed through methods previously known in the art.

Although the invention has been particularly shown and described with reference to a preferred embodiment, it will be understood by those skilled in the art that several changes can be made in the form and detail without departing from the spirit and scope of the invention. In particular, it is understood that the invention of the Applicants can be used to produce a product that has a rolling appearance, made of a number of suitable starting materials, either alone or in combination, such as wheat, rice, oats, sorghum, barley, barley in malt, rye, rye in malt, corn in malt, and other grains or pseudo-cereals such as amaranth, vegetables and legumes such as soybeans, beans, beans, peas, lentils, as well as sources of tuberous starchy starch, such as potatoes, sweet potatoes, cassava, dairy and meat products, such as cheese, cottage cheese, casein / milk caseinates, yogurt , pork and its by-products, beef and its by-products, and chicken meat and its by-products.

Claims

1 .- An apparatus for producing a food piece in the form of a roll, said apparatus comprises: an extruder having at least one hole, where the extruded product exits the extruder through said at least one hole and where in addition The hole comprises a spiral shape.

2. The apparatus according to claim 1, wherein said spiral-shaped hole further comprises at least one and a half turns through the spiral.

3. The apparatus according to claim 1, wherein said spiral hole further comprises a concave end portion.

4. A food piece produced through the apparatus of claim 1.

5. The food piece according to claim 4, wherein said food piece has a length between 0.1 cm and 40 cm.

6.- The food piece according to claim

4, wherein said food piece comprises corn.

7. The food piece according to claim 6, wherein said food piece consists of a corn-based dough.

8.- A method for producing a food roll-shaped piece, said method comprises the steps of: a) preparing a dough; b) extrude said dough through a spiral shaped hole, thus forming a filament of extruded product; c) cutting said filament of extruded product into individual pieces; and d) cooking said individual pieces, in order to produce the roll-shaped food pieces.

9. The method according to claim 8, wherein said dough comprises corn.

10. The method according to claim 9, wherein said dough consists of hydrated corn.

11. The method according to claim 8, wherein said mass comprises between about 45% and about 55% of water by weight before extrusion.

12. The method according to claim 8, wherein the cooking of step d) comprises frying.

13. The method according to claim 8, wherein the filament of extruded product is cut in step c) so that the individual pieces have a length between 3.0 cm and 7.0 cm.